Weatherproof Light String T-Shaped Frame and Piercing Pins
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Solution Overview
Problem
Existing outdoor light string manufacturing processes are inefficient, prone to defects, and costly due to complex multi-step processes, partial stripping of insulation layers, and issues with copper prong insertion and plastic molding, leading to low production efficiency and high failure rates.
Innovation Solution
The use of a T-shaped inner frame and conductive pins with sealing T-shaped connectors formed by plastic injection molding, which simplifies the electrical and mechanical connections between primary and secondary cables, eliminating the need for partial insulation stripping and copper prong bending, and reduces the volume of plastic used, thereby enhancing stability and production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional multi-step manufacturing process with partial insulation stripping and copper prong insertion is used, then electrical connections can be established, but production efficiency is low and manufacturing failure rate is high
Solution Approach 1:
The connector is divided into a housing portion and a separate contact assembly with T-shaped inner frame and conductive pins. This segmentation allows for standardized mass production of components and simplifies the assembly process, thereby improving production efficiency while maintaining connection reliability.
Solution Approach 2:
The T-shaped inner frame acts as an intermediary component that guides and positions the conductive pins during the connection process. This intermediary structure enables automated pin insertion through the insulation layer without requiring manual insulation stripping, thus improving both productivity and reliability.
2Ease of manufacture
If complex multi-step process with insulation stripping and copper prong bending is used, then electrical connections are established, but device complexity increases
Solution Approach 1:
The housing portion and contact assembly are merged into a single integrated connector unit through plastic injection molding. This merging eliminates the need for separate insulation stripping and copper prong bending steps, simplifying the manufacturing process while reducing device complexity.
Solution Approach 2:
The conductive pins are designed to automatically pierce through the insulation layer and establish electrical contact when the connector is assembled. This self-service mechanism eliminates the need for manual insulation stripping and copper prong preparation, greatly simplifying the manufacturing process.
3Reliability
If traditional plastic molding process is used, then sealing is provided, but shrinkage and deformation occur in the final product
Solution Approach 1:
The plastic injection molding process parameters are optimized to control cooling rates and pressure distribution. This parameter optimization reduces shrinkage and deformation while maintaining effective sealing, thereby improving manufacturing precision without compromising reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution results in a more stable and efficient production process with reduced manufacturing failures, improved product durability, and lower costs by automating the connection process and ensuring hermetic sealing, while also addressing issues of shrinkage and deformation in the final product.
Implementation Method 1
a plurality of sealing T-shaped connectors formed by plastic injection molding
Implementation Method 2
The T-shaped inner frame and conductive pins are completely covered within the sealing T-shaped connector
Data Source
AI summary
A weatherproof light string employing a T-shaped inner frame with grooves to direct the placement of a plurality of conductors and apertures to secure conductive pins connecting conductors. The light string has secondary cables connected to the primary cables at one end and lamp holders at the other end. The insulation core wires at the first end of the secondary cable are positioned on the insulation core wires of the first cable by a T-shaped inner frame in a clamping and overlapping manner. Conductive pins extend through a side wall of the T-shaped inner frame and pierce the overlapped insulation core wires to from a mechanical and electrical connection between the wires. Light strings employing the T-shaped inner frame and conductive pins provide a more robust and reliable product, and are better suited to automation. Also disclosed is a method for manufacturing the light string.